Clamps for solar system

ABSTRACT

A solar power system can include a rail and a solar module disposed on the rail. A clamp assembly can couple the solar module to the rail. The clamp assembly can have a clamped configuration in which the solar module is secured to the rail and an unclamped configuration. The clamp assembly can comprise an upper clamp member, a lower clamp member coupled to the rail, and a stabilization member mechanically engaging the upper clamp member and the lower clamp member. The stabilization member can prevent rotation of the lower clamp member relative to the rail when the clamp assembly is in the clamped and unclamped configurations. In the unclamped configuration, the stabilization member can be biased such that the upper clamp member is disposed at a sufficient clearance above the rail to permit the insertion of the solar module between the upper clamp member and the rail.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S.application Ser. No. 16/864,736, filed May 1, 2020, which is acontinuation of U.S. application Ser. No. 16/537,165, filed Aug. 9, 2019(now U.S. Pat. No. 10,680,548, issued Jun. 9, 2020), which is acontinuation of U.S. application Ser. No. 15/383,757, filed Dec. 19,2016 (now U.S. Pat. No. 10,432,133, issued Oct. 1, 2019), which is acontinuation of U.S. application Ser. No. 14/139,755, filed Dec. 23,2013 (now U.S. Pat. No. 9,531,319, issued Dec. 27, 2016). The benefit ofpriority is claimed to each of the foregoing, and the entire contents ofeach of the foregoing are incorporated herein by reference.

BACKGROUND Technical Field

Embodiments of the subject matter described herein relate generally toimproved clamps for solar systems, such as clamps for mounting solarmodules to a mounting structure.

Description of the Related Art

Solar power has long been viewed as an important alternative energysource. To this end, substantial efforts and investments have been madeto develop and improve upon solar energy collection technology. Ofparticular interest are residential-, industrial- and commercial-typeapplications in which relatively significant amounts of solar energy canbe collected and utilized in supplementing or satisfying power needs.One way of implementing solar energy collection technology is byassembling an array of multiple solar modules.

One type of solar energy system is a solar photovoltaic system. Solarphotovoltaic systems (“photovoltaic systems”) can employ solar panelsmade of silicon or other materials (e.g., III-V cells such as GaAs) toconvert sunlight into electricity. Photovoltaic systems typicallyinclude a plurality of photovoltaic (PV) modules (or “solar tiles”)interconnected with wiring to one or more appropriate electricalcomponents (e.g., switches, inverters, junction boxes, etc.).

A typical conventional PV module includes a PV laminate or panel havingan assembly of crystalline or amorphous semiconductor devices (“PVcells”) electrically interconnected and encapsulated within aweather-proof barrier. One or more electrical conductors are housedinside the PV laminate through which the solar-generated current isconducted.

Regardless of an exact construction of the PV laminate, most PVapplications entail placing an array of solar modules at theinstallation site in a location where sunlight is readily present. Thisis especially true for residential, commercial or industrialapplications in which multiple solar modules are desirable forgenerating substantial amounts of energy, with the rooftop of thestructure providing a convenient surface at which the solar modules canbe placed.

In some arrangements, solar modules are placed side-by-side in an array.Each solar module can be mounted to a support structure, such as a roof,by coupling the module to a mounting structure (e.g., a rail) by way ofa coupling member (e.g., a clamp, clip, anchor or mount). It can bechallenging to couple modules side-by-side because the array assemblertypically engages the coupling member while also ensuring that adjacentmodules are positioned properly on the mounting structure. Accordingly,there remains a continuing need for improved systems and methods formounting solar modules to a support structure.

SUMMARY

In one embodiment, a clamp assembly having a major axis is disclosed.The clamp assembly can include an upper clamp member and a lower clampmember. The clamp assembly can further include a stabilization memberhaving a relaxed state and one or more compressed states. Thestabilization member can be configured to prevent rotation of the lowerclamp member relative to the upper clamp member about the major axis.The stabilization member in the relaxed state can be biased to supportat least the weight of the upper clamp member to prevent translation ofthe upper clamp member towards the lower clamp member along the majoraxis.

In another embodiment, a solar power system is disclosed. The solarpower system can comprise a rail and a solar module disposed on therail. The solar power system can include a clamp assembly coupling thesolar module to the rail. The clamp assembly can have a clampedconfiguration in which the solar module is secured to the rail and anunclamped configuration. The clamp assembly can comprise an upper clampmember, a lower clamp member coupled to the rail, and a stabilizationmember mechanically engaging the upper clamp member and the lower clampmember. The stabilization member can prevent rotation of the lower clampmember relative to the rail when the clamp assembly is in the clampedand unclamped configurations. When the clamp assembly is in theunclamped configuration, the stabilization member can be biased suchthat the upper clamp member is disposed at a sufficient clearance abovethe rail to permit the insertion of the solar module between the upperclamp member and the rail.

In yet another embodiment, a method of mounting a solar array to asupport structure is disclosed. The method can include mounting a railto the support structure. The method can further include positioning afirst solar module on the rail. A clamp assembly can be coupled to therail. The clamp assembly can comprise an upper clamp member, a lowerclamp member coupled to the rail, and a stabilization member biased suchthat the upper clamp member is disposed above the rail by a clearance.The stabilization member can prevent rotation of the lower clamp memberrelative to the upper clamp member. The method can further comprisedisposing the first solar module in the clearance between the upperclamp member and the rail. The upper clamp member can be translatedtowards the rail to clamp an edge portion of the first solar modulebetween the upper clamp member and the rail.

In another embodiment, a solar power system is disclosed. The solarpower system can comprise a rail having a groove extending along alength of the rail. The groove can define an aperture between a firstledge and a second ledge. The first ledge can have a first rib extendingalong the length of the rail from the first ledge towards a recess ofthe groove. A lower clamp member can have a lower body disposed in therecess of the groove. The lower body can have an arcuate contact ridgefacing the first rib. When the lower clamp member is clamped against therail, the first rib and the arcuate contact ridge engage to form anelectrical pathway between the lower clamp member and the rail.

In another embodiment, a method for grounding a solar power system isdisclosed. The method can comprise inserting a lower clamp member into agroove of a rail. The groove can extend along a length of the rail. Thelower clamp member can comprise an arcuate contact ridge. The rail cancomprise one or more ribs extending towards the lower clamp member. Themethod can comprise clamping the lower clamp member to the rail suchthat the arcuate contact ridge engages the one or more ribs to createone or more electrical connections between the lower clamp member andthe rail.

In yet another embodiment, a solar power system is disclosed. The solarpower system can comprise a plurality of solar modules. A plurality ofskirt clips can be coupled to the solar modules. One or more skirtsegments can be coupled to the solar modules by way of the skirt clips.

In another embodiment, a skirt clip adapted to couple a skirt to a solararray is disclosed. The skirt clip can comprise a generally Z-shapedmember. The generally Z-shaped member can comprise an upper portion anda lower portion. The generally Z-shaped member can comprise a connectingportion that connects the upper and lower portions. The connectingportion can connect an end of the upper portion with an opposing end ofthe lower portion.

In yet another embodiment, a method of coupling a skirt to an array ofsolar modules is disclosed. The method can comprise forming an array ofsolar modules. The method can further comprise snapping a plurality ofskirt clips to frames of the solar modules. The method can comprisesnapping skirt segments to the plurality of skirt clips to couple theskirt segments to the solar modules.

All of these embodiments are intended to be within the scope of thedisclosure. These and other embodiments will become readily apparent tothose skilled in the art from the following detailed description ofembodiments having reference to the attached figures.

BRIEF DESCRIPTION OF THE DRAWINGS

These aspects and others will be apparent from the following descriptionof various embodiments and the accompanying drawing, which is meant toillustrate and not to limit the disclosure, wherein:

FIG. 1 is a schematic perspective view of a solar power systemcomprising an array of solar modules mounted to a support structure.

FIG. 2 is a magnified perspective view of the solar power systemillustrated in FIG. 1.

FIG. 3 is a schematic diagram of an optional electrical system connectedto the array.

FIG. 4A is a side elevational view of a clamp assembly, according to oneembodiment.

FIG. 4B is a bottom plan view of the clamp assembly of FIG. 4A.

FIG. 5 is an exploded perspective view of the clamp assembly of FIG. 4A.

FIG. 6A is a side elevational view of an upper clamp member, accordingto one embodiment.

FIG. 6B is an orthogonal side elevational view of the upper clamp memberillustrated in FIG. 6A.

FIG. 7 is a side elevational view of a stabilization member, accordingto one embodiment.

FIG. 8 is a perspective view of a lower clamp member, according to oneembodiment.

FIG. 9A is a side elevational view of a rail, according to oneembodiment.

FIG. 9B is a side elevational view of a clamp assembly disposed on therail in an insertion configuration.

FIG. 9C is an orthogonal side elevational view of the clamp assembly andrail illustrated in FIG. 9B.

FIG. 9D is a side elevational view of the clamp assembly coupled to therail in an unclamped configuration.

FIG. 9E is a side elevational view of the clamp assembly coupled to therail in a clamped configuration.

FIG. 9F is an orthogonal side elevational view of the clamp assembly ofFIG. 9D in the unclamped configuration.

FIG. 9G is an orthogonal side elevational view of the clamp assembly ofFIG. 9E in the clamped configuration.

FIG. 10 is a perspective view of a clamp assembly having a stabilizationmember comprising a compressible clip, according to another embodiment.

FIG. 11 is a perspective view of a clamp assembly having a stabilizationmember comprising a spring, according to one embodiment.

FIG. 12 is a perspective view of a clamp assembly having a stabilizationmember comprising a spring, according to another embodiment.

FIG. 13A is a perspective view of a clamp assembly comprising ahook-and-swing mechanism, according to one embodiment.

FIG. 13B is an exploded, perspective view of the clamp assembly of FIG.13A.

FIG. 13C is a side elevational view of the clamp assembly of FIGS.13A-13B coupled to a rail.

FIG. 14 is a flowchart illustrating a method of mounting a solar arrayto a support structure.

FIG. 15A is a side elevational view of the clamp assembly and rail inthe clamped configuration shown in FIG. 9E with a schematicrepresentation of an electrical pathway to ground.

FIG. 15B is a side elevational view a rail, according to one embodiment.

FIG. 15C is a top plan view of the rail shown in FIG. 15B.

FIG. 15D is a side elevational view of a rail having a plurality ofribs, according to one embodiment.

FIG. 15E is a top plan view of the rail shown in FIG. 15D.

FIG. 16 is a flowchart illustrating a method for grounding a solar powersystem, according to one embodiment.

FIG. 17A is a perspective view of a solar module coupled to a skirt byway of a skirt clip, according to one embodiment.

FIG. 17B is an enlarged perspective view of the solar module and skirtclip before attachment of the skirt.

FIG. 17C is an enlarged perspective view of the solar module and skirtclip after attachment of the skirt.

FIG. 17D is a further enlarged perspective view of the skirt clip.

DETAILED DESCRIPTION

The following detailed description is merely illustrative in nature andis not intended to limit the embodiments of the subject matter or theapplication and uses of such embodiments. As used herein, the word“exemplary” means “serving as an example, instance, or illustration.”Any implementation described herein as exemplary is not necessarily tobe construed as preferred or advantageous over other implementations.Furthermore, there is no intention to be bound by any expressed orimplied theory presented in the preceding technical field, background,brief summary or the following detailed description.

This specification includes references to “one embodiment” or “anembodiment.” The appearances of the phrases “in one embodiment” or “inan embodiment” do not necessarily refer to the same embodiment.Particular features, structures, or characteristics may be combined inany suitable manner consistent with this disclosure.

“Configured To.” Various units or components may be described or claimedas “configured to” perform a task or tasks. In such contexts,“configured to” is used to connote structure by indicating that theunits/components include structure that performs those task or tasksduring operation. As such, the unit/component can be said to beconfigured to perform the task even when the specified unit/component isnot currently operational (e.g., is not on/active). Reciting that aunit/circuit/component is “configured to” perform one or more tasks isexpressly intended not to invoke 35 U.S.C. § 112, sixth paragraph, forthat unit/component.

“First,” “Second,” etc. As used herein, these terms are used as labelsfor nouns that they precede, and do not imply any type of ordering(e.g., spatial, temporal, logical, etc.). For example, reference to a“first” solar module does not necessarily imply that this solar moduleis the first solar module in a sequence; instead the term “first” isused to differentiate this solar module from another solar module (e.g.,a “second” solar module).

“Based On.” As used herein, this term is used to describe one or morefactors that affect a determination. This term does not forecloseadditional factors that may affect a determination. That is, adetermination may be solely based on those factors or based, at least inpart, on those factors. Consider the phrase “determine A based on B.”While B may be a factor that affects the determination of A, such aphrase does not foreclose the determination of A from also being basedon C. In other instances, A may be determined based solely on B.

“Coupled”—The following description refers to elements or nodes orfeatures being “coupled” together. As used herein, unless expresslystated otherwise, “coupled” means that one element/node/feature isdirectly or indirectly joined to (or directly or indirectly communicateswith) another element/node/feature.

“Adjust”—Some elements, components, and/or features are described asbeing adjustable or adjusted. As used herein, unless expressly statedotherwise, “adjust” means to position, modify, alter, or dispose anelement or component or portion thereof as suitable to the circumstanceand embodiment. In certain cases, the element or component, or portionthereof, can remain in an unchanged position, state, and/or condition asa result of adjustment, if appropriate or desirable for the embodimentunder the circumstances. In some cases, the element or component can bealtered, changed, or modified to a new position, state, and/or conditionas a result of adjustment, if appropriate or desired

In addition, certain terminology may also be used in the followingdescription for the purpose of reference only, and thus are not intendedto be limiting. For example, terms such as “upper”, “lower”, “above”,and “below” refer to directions in the drawings to which reference ismade. Terms such as “front”, “back”, “rear”, and “side” describe theorientation and/or location of portions of the component within aconsistent but arbitrary frame of reference which is made clear byreference to the text and the associated drawings describing thecomponent under discussion. Such terminology may include the wordsspecifically mentioned above, derivatives thereof, and words of similarimport.

The embodiments disclosed herein are often described in the context ofphotovoltaic arrays and modules. However, these embodiments can be usedin other contexts as well, such as concentrated PV systems, thermalsolar systems, etc.

Various embodiments disclosed herein relate to mounting an array ofsolar modules to a support structure, such as a roof. For example, amounting structure, such as a rail, can be attached to the roof or othersupport structure by way of one or more roof anchors. Solar modules canbe positioned atop the rails adjacent to one another and can be coupledto the rails by way of a coupling member, such as a clamp assembly. Whencoupling adjacent solar modules to the rails, an assembler may encountervarious challenges. For example, the assembler may attempt to align twoadjacent solar modules on the rails, while simultaneously manipulatingthe clamp assembly to clamp the two solar modules to the rails. In somearrangements, it can be challenging to manipulate the clamp assemblywhile also positioning the solar modules relative to one another and therail.

Accordingly, various embodiments disclosed herein are configured toassist an assembler in constructing an array. For example, in someembodiments, a stabilization member is provided to resist or preventrelative rotation between an upper clamp member and a lower clamp memberof the clamp assembly. The stabilization member can be compressible, andcan have a relaxed state and one or more compressible states. In therelaxed state, the stabilization member can be biased to support atleast the weight of the upper clamp member to prevent translation of theupper clamp member towards the lower clamp member relative to therelaxed state. The stabilization member can create a clearance betweenthe upper clamp member and the rail when the clamp assembly is in anunclamped configuration. The clearance can enable an assembler to insertan edge portion of the solar module within the clearance between theupper clamp member and the rail. The assembler can then engage afastener to translate the upper clamp member towards the rail and thelower clamp member to clamp the solar module to the rail.

Besides maintaining the clearance between the upper clamp member and therail (and lower clamp member), the stabilization member can alsomaintain rotational alignment between the lower clamp member and theupper clamp member. For example, the lower clamp member can include anupper locking nut and a lower body member. The stabilization member canresist or prevent rotation between the lower body member and the upperclamp member such that when the lower body member is inserted within agroove of the rail, an aperture of the rail locks the lower body memberin the groove.

In some embodiments, the rail can comprise an elongated piece ofextruded metal. The rail can include a groove having an aperture definedby first and second ledges. In some embodiments, each ledge can includea rib extending downwardly from the ledges towards a recess of thegroove. The rib can include a sharpened distal edge in some embodiments.When the lower body member of the lower clamp member is disposed in therecess of the groove, the rib can mechanically and electrically engagewith an arcuate contact ridge of the lower clamp member when the lowerbody member is clamped against the rail. The contact ridge can assist informing an electrical pathway between the lower clamp member and therail. In some embodiments disclosed herein, multiple ribs can beprovided in each ledge such that multiple electrical pathways are formedbetween the lower clamp member and the rail. By enabling multipleelectrical pathways, the embodiments disclosed herein can improve thedegree of electrical grounding for the solar power system.

In yet other embodiments, a skirt clip is disclosed. The skirt clip canbe configured to clip a skirt to a frame of a solar module. Optionally,the skirt clip can be configured to clip to a frame without additionalbrackets or braces. For example, the skirt clip can comprise a Z-shapedclip having notches along upper and lower portions of the clip. Thenotches can engage with corresponding lips of the solar module and theskirt. By enabling module-level coupling between the skirt and the solararray, the skirt clip can assist in assembling the skirt about aperimeter of the array to hide components underneath the array.

FIG. 1 is a schematic perspective view of a solar power system 100comprising an array 110 of solar modules 112 mounted to a supportstructure 102. FIG. 2 is a magnified perspective view of the solar powersystem 100 illustrated in FIG. 1. The system 100 of FIGS. 1-2 isillustrated as being coupled to a support structure 102 that comprises aroof of a building, such as a residential, commercial, industrialstructure, etc.

The solar module 112 can include a photovoltaic (PV) laminate or panelhaving an assembly of crystalline or amorphous semiconductor devices(“PV cells”) electrically interconnected and encapsulated within aweather-proof barrier that includes a frame. The solar modules 112 canbe mounted on and coupled to spaced apart rails 114 that extend acrossthe support structure 2. The rails 114 can mechanically couple to thesupport structure 2 by way of an anchor in some embodiments.

As shown in FIG. 2, a global x-y-z coordinate system can be definedacross the support structure 2. For example, the rails 114 can extendalong a length in the y-direction, and the array 110 can be positionedatop the rails 114 in the x-y plane. As used herein, the x-y-zcoordinate system shown in FIG. 2 defines a global frame of referencefor the solar modules 112 and other components disclosed herein.

FIG. 3 is a schematic diagram of an optional electrical system 40connected to the array. The solar power system 100 can be incorporatedinto the electrical system 40 connected to the array 110. For example,the electrical system 40 can include the array 110 as a power sourceconnected to a remote connection device 42 with power lines 44. Theelectrical system 40 can also include a utility power source, a meter,an electrical panel with a main disconnect, a junction, electricalloads, and/or an inverter with the utility power source monitor. Theelectrical system 40 can be configured and can operate in accordancewith the descriptions set forth in U.S. patent application Ser. No.12/371,315, to Peurach et al., published as U.S. Patent Publication No.2010/0071744, and entitled “Photovoltaic Installation with AutomaticDisconnect Device.” the entire contents of which are hereby expresslyincorporated by reference in its entirety for all purposes.

FIG. 4A is a side elevational view of a clamp assembly 101, according toone embodiment. As explained herein, the clamp assembly 101 can coupleadjacent solar modules 112 to rails 114, e.g., between adjacent modules112. In other embodiments, the clamp assembly 101 can be disposed at anouter end of the array 110 such that the clamp assembly 101 only couplesto one module 12 along a perimeter of the array 110. FIG. 4B is a bottomplan view of the clamp assembly 101 of FIG. 4A. FIG. 5 is an explodedperspective view of the clamp assembly 101 of FIGS. 4A-4B. As explainedabove, it can be advantageous to provide a clamp assembly in which theassembler can align and secure adjacent solar modules to the frame.

As shown in FIGS. 4A-5, the clamp assembly 101 can include an upperclamp member 103 and a lower clamp member 108. A stabilization member105 can be disposed between the upper clamp member 103 and the lowerclamp member 108. A fastener 104 can extend between the upper clampmember 103 and the lower clamp member 108.

For example, the fastener 104 can extend through a washer 107, anopening 113 of the upper clamp member 103, an opening 119 of thestabilization member 105, and into an opening 111 of the lower clampmember 108. The fastener 104 can comprise any suitable threadedfastener, such as a bolt. The fastener 104 can threadably engage withthe lower clamp member 108 in some embodiments such that rotation of thefastener 104 relative to the lower clamp member 108 causes the fastener104 to clamp downwards and towards the lower clamp member 108.

As shown in FIG. 5, a local u-v-w coordinate system can be used todescribe the orientation of the clamp assembly 101. In general, thelocal w coordinate can correspond to the global z coordinate. The w-axiscan represent a major axis of the clamp assembly 101. The u-axis canrepresent a lateral axis representative of width, and the v-axis canrepresent a longitudinal axis representative of length.

FIG. 6A is a side elevational view of the upper clamp member 103,according to one embodiment. FIG. 6B is an orthogonal side elevationalview of the upper clamp member 103 illustrated in FIG. 6A. Withreference to FIGS. 5 and 6A-6B, the fastener 104 can extend through theopening 113 of the upper clamp member 103. The upper clamp member 103can include a first arm 123 a and a second arm 123 b extending outwardlyfrom the major axis w along the longitudinal axis v.

A first projection 116 a or tooth and a second projection 116 b or toothcan extend from a distal portion of each arm 123 a, 123 b. Theprojections 116 a, 116 b can extend downwardly along the major axis wtowards the lower clamp member 108. As shown in FIG. 6B, the firstprojection 116 a and the second projection 116 b can be spaced apartalong the lateral axis u to form a support edge 124. As explained belowwith respect to FIG. 7, the stabilization member 105 can mechanicallylevitate the upper member 103 by supporting the upper clamp member 103along the support edge 124. As explained herein, the projections 116,116 b can be configured to secure a solar module to a mounting structuresuch as a rail 114. Although the upper clamp member 103 shown in FIGS.6A-6B includes projections 116 a, 116 b extending from arms 123 a, 123b, in other embodiments, the upper clamp member 103 may not include anyprojections. For example, in some embodiments (see, e.g., FIG. 12), theupper clamp member can include arms extending from a central body, andthe arms can be clamped downwardly against an upper or other surface ofa solar module 112. In other embodiments, the clamp member 103 may onlycouple to solar modules 112 along the perimeter of the array 110, e.g.,the clamp member 103 can comprise an end clamp that clamps outer modules112 to the rail or other mounting structure.

FIG. 7 is a side elevational view of the stabilization member 105,according to one embodiment. The stabilization member 105 can becompressible, such that the stabilization member 105 includes a relaxedstate and one or more compressed states. In the relaxed state, thestabilization member 105 can be biased outwardly along the major axis w.In the compressed state(s), stabilization member 105 can be compressedinwardly along the major axis w. The stabilization member 105 can beconstructed of a plastic, such as a polyvinyl chloride (PVC) or anyother suitable polymer.

In some embodiments, the stabilization member 105 can be extruded alongthe lateral axis u. By using an extruded stabilization member 105,simplified methods of construction can be enabled. For example, acomplex or otherwise arbitrary cross-section can be defined, and thestabilization member 105 can be extruded to form the finalthree-dimensional structure. The stabilization member 105 of FIG. 7 isshown in the relaxed state, in which there are no or minimal externalforces applied to the stabilization member 105.

With reference to FIGS. 5-7, the stabilization member 105 can define agenerally X-shaped cross-section. For example, the stabilization member105 can include a central portion 117 having a first upwardly-extendingflange 115 a and a second upwardly-extending flange 115 b.

As shown in FIG. 5A, the upwardly-extending flanges 115 a, 115 b can beconfigured to support the first and second arms 123 a, 123 b of theupper clamp member 103, e.g., at the support edge 124 (see FIGS. 5-6B).The first and second arms 123 a, 123 b and corresponding projections 116a, 116 b can prevent rotation of the stabilization member 105 relativeto the upper clamp member 103. As explained herein, the stabilizationmember 105 can also prevent relative rotation between the stabilizationmember 105 and the lower clamp member 108. The stabilization member 105can accordingly maintain the orientation of the upper clamp member 103relative to the lower clamp member 108, such that the lower clamp member108 does not rotate relative to the upper clamp member 103.

A first downwardly-extending flange 120 a and a seconddownwardly-extending flange 120 b can extend from the central portion117. A first distal foot 125 a and a second distal foot 125 b can extendfrom distal portions of the downwardly-extending flanges 120 a, 120 b.The central portion 117 can also include a C-shaped channel 121 facingthe lower clamp member 108 (see FIG. 5). The C-shaped channel 121 candefine first and second inwardly-extending projections 126 a, 126 b.

FIG. 8 is a perspective view of the lower clamp member 108, according toone embodiment. The lower clamp member 108 can comprise an upper lockingnut 109 having a threaded opening 111 therethrough. The lower clampmember 108 can also include a lower body member 122 having a lengthalong the longitudinal direction v and a width along the lateraldirection u. As shown in FIG. 8, the length of the lower body member 122along the longitudinal direction v can be larger than a major dimensionof the upper locking nut 109, e.g., the largest dimension of the nut109.

With reference to FIGS. 5 and 7, the C-shaped channel 121 can capturethe upper locking nut 109 therein such that the inwardly-extendingprojections 126 a, 126 b prevent the upper locking nut 109 fromtranslating out of the channel 121 in the w-direction (the major axis).An arcuate contact ridge 127 can extend upwardly from the lower bodymember 122. The contact ridge 127 can include a sharp distal edge toenhance mechanical and electrical coupling between the lower body member122 and the rail 114 to create a grounded electrical pathway between thelower body member 122 and the rail 114.

FIG. 9A is a side elevational view of a rail, according to oneembodiment. The rail 114 can include a groove 128 that defines a recessalong a length of the rail, e.g., in the y-direction. The groove 128 candefine an aperture 129 of the rail 114 between a first ledge 131 a and asecond ledge 131 b. With reference to FIGS. 8 and 9A, the length of thelower body member 122 along the longitudinal direction v may be largerthan a width of the aperture 129. The width of the lower body member 122along the lateral direction u may be smaller than the width of theaperture 129 of the rail 114.

FIG. 9B is a side elevational view of the clamp assembly 101 disposed onthe rail 114 in an insertion configuration. FIG. 9C is an orthogonalside elevational view of the clamp assembly 101 and rail 114 illustratedin FIG. 9B. In the insertion configuration, the clamp assembly 101 maybe inserted into the groove 128 of the rail 114. To insert the lowerbody member 122 into the recess of the groove 128, the clamp assembly101 can be aligned relative to the rail 114 such that the lateral axis uof the clamp assembly 101 generally aligns with the aperture 129, e.g.,such that the lateral axis u of the clamp assembly 101 aligns with thex-axis of the array 110. As shown in FIG. 9B, the feet 125 a, 125 b ofthe stabilization member 105 can rest against a top mounting surface ofthe rail 114. The width of the lower clamp member 108 can be less thanthe width of the aperture 129 such that the lower clamp member 108 canbe inserted through the aperture 129 and into the groove 128. As shownin FIGS. 9B-9C, the stabilization member 105 is in a relaxedconfiguration such that the stabilization member 105 supports the weightof the upper clamp member 103. The stabilization member 105 thereby canact to maintain a separation distance or clearance between the upperclamp member 103 and the rail 114.

The clamp assembly 101 in the insertion configuration of FIGS. 9B-9C canbe used to initiate the coupling of the clamp assembly 101 to the rail114. To secure the clamp assembly 101 to the rail 114, the clampassembly 101 can be rotated by about 90° to place the clamp assembly inan unclamped configuration that prevents vertical translation of theclamp assembly 101 relative to the rail 114 in the z- and w-directions.FIG. 9D is a side elevational view of the clamp assembly 101 coupled tothe rail 114 in an unclamped configuration. Upon rotating the clampassembly 101 by about 90°, the lower clamp member 108 can be disposed inthe groove 128 such that the first ledge 131 a and the second ledge 131b that define the aperture 129 capture the lower clamp member 108 in therecess of the groove 128. For example, as shown in FIGS. 8 and 9D, thelength of the lower body member 122 along the longitudinal v directioncan be greater than the width of the aperture 129 (see FIG. 9A). Thefirst and second ledges 131 a, 131 b of the aperture 129 can capture thelower body member 122 of the lower clamp body 108 to prevent the lowerclamp body 108 from translating along the major axis in the w-direction.

In the unclamped configuration, the stabilization member 105 may be in arelaxed state or a slightly compressed state. For example, to rotate thelower body member 122, the stabilization member 105 may be slightlycompressed along the w-direction to position the lower body member 122in the groove 128. In some arrangements, the stabilization member 105may not be compressed and may be in the relaxed state when in theunclamped configuration. The feet 125 a, 125 b can help align the upperclamp member 103 (by way of the arms 123 a, 123 b) to the rail 114. Inthe unclamped configuration shown in FIG. 9D, the stabilization member105 can support the upper clamp member 103 at an unclamped clearanceheight h_(u) defined between the support edge 124 (FIG. 6B) and the topmounting surface of the rail 114. Thus, in the unclamped configuration,the stabilization member 105 can support at least the weight of theupper clamp member 103.

FIG. 9F is an orthogonal side elevational view of the clamp assembly 101of FIG. 9D in the unclamped configuration. As shown in FIG. 9F, theclamp assembly 101 can be used to couple two adjacent solar modules 112a, 112 b to the rail 114. Each solar module 112 a, 112 b can include acorresponding frame 106 a, 106 b around a periphery of the module. Theframes 106 a, 106 b can each include a lip 118 a, 118 b sized and shapedto engage with the clamp assembly 101. For example in the unclampedconfiguration of FIG. 9F, the stabilization member 105 can levitate theupper clamp member 103 such that the lips 118 a, 118 b of the frames 106a, 106 b can be inserted through the clearance of the unclamped heighth_(u). Accordingly, in the unclamped configuration, the lateral width uof the clamp assembly 101 can be disposed along the y-direction of thearray 110. The unclamped clearance height h_(u) between the upper clampmember 103 and the rail 114 can allow the assembler to insert the lips118 a, 118 b of the modules 112 a, 112 b underneath the projections 116a, 116 b of the upper clamp member 103. Advantageously, thestabilization member 105 can be biased such that the upper clamp member103 is disposed above the lips 118 a, 118 b during assembly. Theassembler can thereby position adjacent modules 112 a, 112 b as desired.

FIG. 9E is a side elevational view of the clamp assembly 101 coupled tothe rail 114 in a clamped configuration. FIG. 9G is an orthogonal sideelevational view of the clamp assembly 101 of FIG. 9E in the clampedconfiguration. In the clamped configuration of FIGS. 9E and 9G, theassembly 101 can clamp the upper clamp member 103 against the frame 106a, 106 b of the solar module 112 a, 112 b and the rail 114. For example,the assembler can rotate or otherwise actuate the fastener 104 such thatthe fastener 104 translates the upper clamp member 103 towards the lowerclamp member 108 along the major axis w. Translating the upper clampmember 103 towards the lower clamp member 108 can compress thestabilization member 105 from a relaxed or slightly compressed state toa compressed and/or substantially (or fully) compressed state. When theclamp assembly 101 is in the clamped configuration of FIGS. 9E and 9G,the upper clamp member 103 can be at a clamped height h_(c) that islower than the unclamped height h_(u) shown in FIG. 9D. Indeed, as shownin FIG. 9G, the projections 116 a, 116 b can capture the correspondinglips 118 a, 118 b of the frames 106 a, 106 b of the adjacent modules 112a, 112 b against the rail 114. Accordingly, the fastener 104 can betranslated by an amount δ=h_(u)−h_(c) to move the clamp assembly 101from the unclamped configuration to the clamped configuration to securethe solar modules 112 a, 112 b to the rail 114.

Accordingly, the stabilization member 105 can advantageously act tolevitate the upper clamp member 103 at a sufficient unclamped clearanceheight h_(u) such that adjacent modules can be inserted between theclamp assembly 101 and the rail 114. In addition, the stabilizationmember 105 can advantageously maintain a relative orientation betweenthe upper clamp member 103 and lower clamp member 108 such that in theunclamped and clamped configurations, the lower clamp member 108 doesnot rotate relative to the upper clamp member 103. Advantageously, thestabilization member 105 can also prevent rotation between the lowerclamp member 108 and the groove 128 of the rail 114.

FIG. 10 is a perspective view of a clamp assembly 201 having astabilization member 205 comprising a compressible clip, according toanother embodiment. The embodiment of FIG. 10 is generally similar tothe embodiment disclosed above with respect to FIGS. 4A-9G. For example,the clamp assembly 201 can include an upper clamp member 203 and a lowerclamp member 208. The stabilization member 205 can be provided toprevent relative rotation between the upper clamp member 203 and thelower clamp member 208. The stabilization member 205 can also be biasedto support the upper clamp member 203 when the stabilization member 205is uncompressed or slightly compressed. An opening 213 can be formedthrough the assembly 201 to receive a fastener for directly coupling theupper clamp member 203 with the lower clamp member 208. As above, theupper clamp member can include first and second arms 223 a extendingfrom a major axis. Downwardly-extending projections 216 a, 216 b canextend from the arms 223 a, 223 b towards the lower clamp member 208 andcan be adapted to secure adjacent solar modules to a rail.

FIG. 11 is a perspective view of a clamp assembly 301 having astabilization member 305 comprising a spring, according to oneembodiment. The stabilization member 305 can operate in a mannergenerally similar to that explained with respect to the embodiments ofFIGS. 4A-10. For example, the assembly 301 can include an upper clampbody 303 and a lower clamp body 308. A fastener 304 can pass through theupper clamp body 303 and can threadably couple with the lower clamp body308. The upper clamp body 303 can include first and second arms 323 a,323 b and one or more teeth 316 configured to secure a portion of asolar module to a rail. The stabilization member 305 of FIG. 11 cancomprise a spring extending between an upper locking portion 333 and alower locking portion 334. The stabilization member 305, e.g., thespring, can act to bias the clamp assembly 301 along the major axis w.Further, the locking portions 333, 334 can be configured tosubstantially prevent relative rotation between the upper clamp member303 and the lower clamp member 308. Thus, as explained herein, thestabilization member 305 can similarly assist in the assembly andmaintenance of the array 110 of solar modules 112.

FIG. 12 is a perspective view of a clamp assembly 401 having astabilization member 405 comprising a spring, according to anotherembodiment. The stabilization member 405 can operate in a mannergenerally similar to that explained with respect to the embodiments ofFIGS. 4A-11. For example, an upper clamp member 403 can couple to alower clamp member 408 by way of a fastener 404. The fastener 404 can bethreadably engaged with the lower clamp member 408 in some arrangements.The upper clamp member 403 can include first and second arms 423 a, 423b extending from the major axis. Unlike the embodiment of FIGS. 6A-6B,however, the arms 423 a, 423 b do not capture the modules by way ofdownwardly extending projections. Rather, the first and second arms 423a, 423 b can capture an edge portion of a solar module between the arms423 a, 423 b and the rail. Thus, the embodiments disclosed herein, suchas that disclosed in FIG. 12, can be used to clamp edge portions of asolar module, including modules that do not include the lips disclosedherein. As above, the stabilization member 405 can comprise a springextending between locking portions 433, 434 to support the upper clampmember 403 and prevent rotation of the upper clamp member 403 relativeto the lower clamp member 408.

FIG. 13A is a perspective view of a clamp assembly 501 comprising ahook-and-swing mechanism, according to one embodiment. FIG. 13B is anexploded, perspective view of the clamp assembly 501 of FIG. 13A. Asshown in FIGS. 13A-13B, the clamp assembly 501 can include an upperclamp member 503 and a lower clamp member 508 sized and shaped to bereceived by a rail. An arm 523 a and a projection 516 a extending from adistal portion of the arm 523 a can be used to couple a solar module toa rail. A stabilization member 505 can couple the upper clamp member 503with the lower clamp member 508. For example, the stabilization member505 can include arms that extend about and capture the upper clampmember 503. The lower clamp member 508 can be disposed in a lowerportion of the stabilization member 505. As above, the stabilizationmember 505 can assist in levitating and supporting the upper clampmember 503 relative to the rail, while maintaining the relativeorientation between the lower clamp member 508 and the upper clampmember 503. FIG. 13C is a side elevational view of the clamp assembly501 of FIGS. 13A-13B coupled to a rail 514. As shown in FIG. 13C, theprojection 516 a can be captured by a frame 506 of the module. In someembodiments, the clamp assembly 501 can couple the frame 506 to the rail514 by way of a hook and swing motion in which the projection 516 a ishooked into the corresponding groove of the frame 506. Frame 506 andsolar module can be swung into place along the rail 514 and clamped tothe rail 514.

FIG. 14 is a flowchart illustrating a method 800 of mounting a solararray to a support structure. The method 800 begins in a block 801 tomount a rail to a support structure, such as a roof. The rail can beattached to the support structure by way of, e.g., a brace or bracket.The rail can include a groove having a recess along a length of therail. The method 800 can move to a block 803 to position a first solarmodule on the rail. The first solar module can comprise a photovoltaiccell enclosed within a frame, in some arrangements.

The method 800 can move to a block 805 to couple a clamp assembly to therail. The clamp assembly can include an upper clamp member, a lowerclamp member coupled to the rail, and a stabilization member biased suchthat the upper clamp member is disposed above the rail by a clearance.The stabilization member can prevent rotation of the lower clamp memberrelative to the upper clamp member. In some embodiments, the lower clampmember can include a lower body having a length and a width smaller thanthe length. The lower body can be inserted into the groove of the railsuch that the length of the lower body is substantially aligned with thelength of the rail. The lower body of the lower clamp member can berotated such that the length of the lower body is transverse to thelength of the rail and such that a lower portion of the stabilizationmember engages the rail.

Turning to a block 807, the first solar module can be disposed in theclearance between the upper clamp member and the rail. In someembodiments, a second solar module is positioned on the rail adjacentthe first solar module. The second solar module can be disposed in theclearance between the upper clamp member and the rail.

The method moves to a block 809 to translate the upper clamp membertowards the rail to clamp an edge portion of the first solar modulebetween the upper clamp member and the rail. An edge portion of thesecond solar module can also be clamped between the upper clamp memberand the rail.

It can be important in various arrangements to ensure that thecomponents of the system 100 are grounded. For example, grounding systemcomponents can improve the safety of the system and/or can maintainsystem performance. FIG. 15A is a side elevational view of the clampassembly 602 and rail 614 in the clamped configuration shown in FIG. 9Ewith a schematic representation of an electrical pathway 636 to ground.As shown in FIG. 15A, the arms 623 a, 623 b of the upper clamp member603 can mechanically engage with the solar module, e.g., with a portionof the frame. For example, the arms 623 a, 623 b can cut into orotherwise mechanically compress against the module to create anelectrical pathway 636 between the upper clamp body 603 and the module.

The electrical pathway 636 can pass through the upper clamp body 603 andinto the fastener 604 by way of the washer 607. The pathway 636 can passalong the length of the fastener 604 and can couple to the lower clampmember 608 by way of the threaded connection. The electrical pathway 636can pass from the lower clamp member 608 to the rail 614 by way of thearcuate contact ridges 127 shown in FIG. 8. Thus, the electrical pathway636 can couple between the upper clamp member 603 and the fastener 604at contact point 637. The pathway 636 can pass from the fastener 638 tothe lower clamp member 608 at contact point 638, and can pass from thelower clamp member 608 to the rail by way of the ridges 127 at contactpoint 639.

FIG. 15B is a side elevational view of a rail 614, according to oneembodiment. FIG. 15C is a top plan view of the rail shown in FIG. 15B.For example, the arcuate contact ridge 127 of the lower clamp member 108can bear against the ledges 631 a, 631 b and create an electricalpathway therebetween. It can be advantageous, however, to improve theelectrical connection between the rail 614 and the lower clamp member108 to improve the grounding of the system 100.

FIG. 15D illustrates a rail 614A having a plurality of ribs 632,according to one embodiment. FIG. 15E is a top plan view of the rail614A shown in FIG. 15D. The ribs 632 can comprise sharpened projectionsextending downwardly from the ledges 631 a, 631 b towards the recess ofthe groove 628. The ribs 632 can be extruded with the rail 614A. Thus,because the ribs 632 can be defined with the cross-section of the rail614A, any suitable number of ribs 632 can be included in the rail 614A.Extruding the ribs 632 can be relatively simple and cost effective froma manufacturing standpoint.

Multiple ribs 632 extending from the ledges 631 a, 631 b can createmultiple electrical contact points 635 and multiple correspondingelectrical pathways when the lower clamp member 608 is clamped againstthe rail 614A. For example, as shown in FIG. 15D, the intersectionbetween the arcuate contact ridge 127 of the lower clamp member 108 andthe ribs 632 can form a plurality of contact points 635 and electricalpathways to ground. Because the ribs 632 are relatively sharp, thecontact area can be reduced, and the interfacial pressure can beincreased, which can accordingly increase the electrical conductancebetween the lower clamp member 108 and the rail 614A. Thus, at leastbecause the multiple ribs 632 create multiple electrical pathways 636,the embodiment of FIGS. 15D-15E can improve the grounding of the system100 relative to other arrangements.

FIG. 16 is a flowchart illustrating a method 900 for grounding a solarpower system, according to one embodiment. The method 900 begins in ablock 901 to insert a lower clamp member into a groove of a rail. Thegroove can extend along a length of the rail. The lower clamp member cancomprise an arcuate contact ridge. The rail can comprise multiple ribsextending towards the lower clamp member from ledges that define anaperture of the rail.

The method 900 moves to a block 903 to clamp the lower clamp member tothe rail such that the arcuate contact ridges engage one or more ribs ofthe rail. As explained herein, providing multiple ribs can createmultiple electrical pathways between the lower clamp member and therail. By creating multiple electrical pathways between the rail and theclamp assembly, the grounding of the system can be improved.

In other embodiments disclosed herein, it can be advantageous to providea skirt about a periphery of the array 110. For example, electricaland/or mechanical components (such as wires, fasteners, other hardware,etc.) can be provided underneath the array 110. For aesthetic purposes,it can be desirable to hide the components underneath the array 110.Furthermore, it can be desirable to directly couple the skirt to thesolar module itself (rather than to the mounting structure, such as abrace or rail) so that the skirt can be provided about the entireperimeter of the array 110 regardless of the shape of the array.

FIG. 17A is a perspective view of a solar module 712 coupled to a skirt755 by way of a skirt clip 750, according to one embodiment. The skirtclip 750 of FIG. 17A can directly couple the skirt 755 to the moduleframe 706 rather than to external mounting components, such as a rail orbrace. By coupling to the frame 706 of the solar module 712, the skirt755 can be applied about any arbitrary perimeter of the array 110. Theskirt 755 can be applied about the perimeter of the array 110 inmultiple skirt segments. For example, multiple skirt segments can becoupled to the perimeter of the array 110 adjacent one another to form asubstantially continuous skirt about the periphery of the solar array110.

FIG. 17B is an enlarged perspective view of the solar module 712 andskirt clip 750 before attachment of the skirt 755. FIG. 17C is anenlarged perspective view of the solar module 712 and skirt clip 750after attachment of the skirt 755. As shown in FIG. 17B, the skirt clip750 can be snapped into place along the perimeter of the module 712. Forexample, the skirt clip 750 can snap into a lip 756 of the module 712 tocouple the clip 750 to the module 712. Upon snapping the clip 750 to themodule 712, the skirt clip 750 can similarly be snapped into place alongthe skirt 755, as shown in FIG. 17C. For example, the skirt clip 750 cansnap into a corresponding lip 757 of the skirt 755. Accordingly, in someembodiments, the skirt 755 can have lips 757 that generally mirrorcorresponding lips 756 of the frame 706 of the solar module 712. Themirror symmetry of the skirt 755 and skirt clip 750 can enable theapplication of the skirt 755 about any suitable perimeter of an array110.

FIG. 17D is a further enlarged perspective view of the skirt clip 750shown in FIGS. 17A-17C. The skirt clip 750 can comprise an upper portion761, a lower portion 762, and a connecting portion 759 that connects theupper and lower portions 761, 762. As shown in FIG. 17D, the skirt clip750 can define a generally Z-shaped cross-section such that a first endof the connecting portion 759 connects one end of the upper portion 761with an opposing end of the lower portion 762. The upper portion 761 andthe lower portion 762 can each define two slots 758 sized and shaped toengage corresponding lips 756 of the solar module 712 and lips 757 ofthe skirt 755. The slots 758 and corresponding lips 756, 757 can engagein a snap-fit connection to couple the skirt 755 to the solar module 712by way of the skirt clip 750.

To couple the skirt 755 to the module 712, the assembler can assemblethe array 110 to any desired size and defining any suitable perimeter.The assembler can snap a plurality of clips to outer portions of framesof the solar modules. As explained herein, the assembler can snap slots758 of the clip 750 with corresponding lips 756 of the solar modules712. The assembler can also snap the clips to inner portions of theskirt 755. For example, slots 758 can be snapped into corresponding lips757 of the skirt 755 to couple the skirt 755 to the array 110. Becausethe skirt 755 is coupled directly to the modules 712, the skirt 755 canbe applied about any suitable perimeter of the array 110.

Although specific embodiments have been described above, theseembodiments are not intended to limit the scope of the presentdisclosure, even where only a single embodiment is described withrespect to a particular feature. Examples of features provided in thedisclosure are intended to be illustrative rather than restrictiveunless stated otherwise. The above description is intended to cover suchalternatives, modifications, and equivalents as would be apparent to aperson skilled in the art having the benefit of this disclosure.

The scope of the present disclosure includes any feature or combinationof features disclosed herein (either explicitly or implicitly), or anygeneralization thereof, whether or not it mitigates any or all of theproblems addressed herein. Accordingly, new claims may be formulatedduring prosecution of this application (or an application claimingpriority thereto) to any such combination of features. In particular,with reference to the appended claims, features from dependent claimsmay be combined with those of the independent claims and features fromrespective independent claims may be combined in any appropriate mannerand not merely in the specific combinations enumerated in the appendedclaims.

What is claimed is:
 1. A solar module clamp assembly having a majoraxis, the solar module clamp assembly comprising: an upper clamp member;a lower clamp member; a fastener extending along the major axis andcoupling the upper clamp member with the lower clamp member; and astabilization member positioned between the upper clamp member and thelower claim member, the stabilization member being configured to supportthe upper clamp member at a position vertically spaced above the lowerclamp member, the stabilization member having a relaxed state and one ormore compressed states, wherein the stabilization member in the relaxedstate prevents translation of the upper clamp member towards the lowerclamp member along the major axis, wherein the stabilization member inthe one or more compressed states is compressed such that the upperclamp member is translated towards the lower clamp member along themajor axis relative to the relaxed state, and wherein the upper clampmember has a first arm and a second arm extending in opposite directionsperpendicular to the major axis, the first arm being adapted to secure afirst solar module to a mounting structure and the second arm beingadapted to secure a second solar module to the mounting structure.